System and method for integrally serializing a cast part

ABSTRACT

A method of serializing a cast part includes providing a mold for a metal casting, with the mold including an inner face partially defining a part cavity; laser engraving a representation of the two-dimensional data matrix into the inner face of the mold; and forming a serialized part by pouring molten metal into the part cavity of the mold, where the molten metal fills the part cavity including the engraved representation of the two-dimensional data matrix. The two-dimensional data matrix being generated by an electronic controller and includes error correcting information and part identifying information.

TECHNICAL FIELD

The present invention relates generally to systems and methods of serializing a cast part.

BACKGROUND

In manufacturing, casting involves pouring liquid metal into a mold, which contains a hollow cavity of the desired shape, and then allowing it to cool and solidify. The solidified part (i.e., cast part) may then be ejected or broken out of the mold to complete the process. Casting is most often used for making complex shapes that would be difficult or uneconomical to make by other methods.

Sacrificial sand-molds may be mass-produced by forming sand and a bonding-agent around a rigid metal pattern. Once the sand and bonding agent are compacted and hardened, the pattern may be removed, leaving a mold with a negative space (cavity) where the pattern originally was placed. This cavity may then receive the liquid metal to form the cast part. To uniquely identify the finished cast part (such as with a serial number), secondary processes such as labeling, imprinting, scribing, or etching can be used to apply part identifying information to the part. These processes, however, require additional manufacturing steps, or produce an identifier that may be easily worn away (such as with labels).

SUMMARY

A method of serializing a cast part includes: providing a mold for a metal casting, with the mold including an inner face partially defining a part cavity; laser engraving a representation of the two-dimensional data matrix into the inner face of the mold; and pouring molten metal into the part cavity of the mold, wherein the molten metal fills the part cavity including the engraved representation of the two-dimensional data matrix. The laser engraved data matrix may be engraved into the inner face to a depth of between approximately 0.5 mm and approximately 1.5 mm. Additionally, alphanumeric part identifying information may also be engraved into the inner face of the mold proximate to the engraved representation of the two-dimensional data matrix.

The representation of the two-dimensional data matrix may be generated using an electronic controller and may include error correcting information and part identifying information. In one configuration, the error correcting information is generated according to a Reed-Solomon Error Correcting Code. Likewise, the part identifying information may include a part serial number and a part model identifier, and may further include a manufacturing location identifier and a manufacturing date identifier. The two-dimensional data matrix may be, for example, a QR Code generated according to ISO/IEC 18004:2006 or a Data Matrix ECC200 Code generated according to ISO/IEC 16022:2006.

In one configuration, the part serial number may be stored in a computer readable database. Additionally at least one manufacturing parameter associated with the forming of the serialized part may be monitored, stored in the computer readable database, and associated with the stored part serial number. The at least one monitored manufacturing parameter may include at least one of a mold temperature and cooling rate

A system for serializing a cast part may include a mold for a creating a cast metal part, an electronically controlled laser engraving device configured to selectively engrave the inner face of the mold, and an electronic controller. The mold may include an inner face partially defining a part cavity.

The electronic controller may be configured to generate a two-dimensional data matrix, wherein the two-dimensional data matrix includes error correcting information and part identifying information. Subsequently, the electronic controller may control the laser engraving device to engrave a representation of the two-dimensional data matrix into the inner face of the mold. The engraved mold may then be used to form a serialized cast part having an integrally formed two-dimensional data matrix upon receipt of molten metal within the part cavity.

The above features and advantages and other features and advantages of the present invention are readily apparent from the following detailed description of the best modes for carrying out the invention when taken in connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is schematic partial cross-sectional view of a laser engraving system being operated to engrave an inner face of a part-casting mold.

FIG. 2 is a schematic plan view of a mirror image of a Data Matrix ECC200 Code engraved into an inner face of a part-casting mold.

FIG. 3 is a schematic plan view of a mirror image of a QR Code engraved into an inner face of a part-casting mold.

FIG. 4 is a is a schematic plan view of a mirror image of a Data Matrix ECC200 Code engraved into an inner face of a part-casting mold proximate to alphanumeric part identifying information.

FIG. 5 is a flow diagram of a method of serializing a cast part.

DETAILED DESCRIPTION

Referring to the drawings, wherein like reference numerals are used to identify like or identical components in the various views, FIG. 1 schematically illustrates a system 10 for incorporating an integral unique identifier into a cast part (i.e., “serializing” the cast part). The system 10 may include a mold 20 for creating the cast metal part, an electronically controlled laser engraving device 30, and an electronic controller 40.

The mold 20 may include an inner face 22 that may partially define a part cavity 24. As may be appreciated, the mold 20 illustrated in FIG. 1 may be a lower mold of a larger mold assembly that may more completely define the part cavity 24. The mold 20 may be a sand-based mold 20, such as may be used to form a metal part through processes generally referred to as “sand casting” or “sand molded casting.” Such sand-based molds may include a silica-based sand (or other suitable inert granular sand) along with a bonding agent that may allow the sand to retain its shape following the creation of the mold 20. In one configuration, the part cavity 24 may resemble, and be used to cast an engine block for an automotive vehicle.

During a casting process, molten metal may be poured, drawn, or injected into the part cavity 24 of the mold 20. The molten metal may substantially fill the mold, and upon cooling, may solidify to form the cast part. The mold 20 may then be removed (often in a sacrificial manner), leaving only the solidified metal casting. Other suitable casting techniques as known in the art may be employed to perfect the shape and/or quality of the solidified cast part.

Prior to the casting process, the inner face 22 of the mold 20 may be engraved with a unique identifier, such as using the electronically controlled laser engraving device 30. During the casting process, molten metal may then substantially fill the engraved identifier in addition to the part cavity 24. This may result in the identifier appearing in a raised manner from the surface of the solidified cast part.

The laser engraving device 30 may generally include a power supply 32 and a position controller 34. The power supply 32 may control the power of the laser 36, which may, in turn, control the depth of the engraving. Likewise, the position controller 34 may control the position and/or angle of the laser 36 in space. By modulating the power (via the power supply 32) and controlling the position (via the position controller 34), the laser engraving device 30 may selectively remove material from the inner face 22 of the mold 20 throughout a two-dimensional area.

As mentioned above, the system 10 may further include an electronic controller 40 that may be adapted to control the operation of the laser engraving device 30. For example, the controller 40 may be configured to control the laser engraving device 30 to engrave a mirror image of the unique identifier into the inner face 22 of the mold 20. In one configuration, the unique identifier may be a two-dimensional (2D) data matrix 50, such as generally illustrated in FIGS. 2 and 3. In this application, a data matrix 50 may have numerous benefits over serializing solely with alphanumeric text. These benefits may include the ability to represent identifying information at a greater density, the ability to provide error correction and/or enhanced robustness, and the ability to be more easily (and consistently) read by machine vision systems, even in the presence of flaws in the casting.

The electronic controller 40 may be embodied as one or multiple digital computers or data processing devices, each having one or more microprocessors or central processing units (CPU), read only memory (ROM), random access memory (RAM), electrically-erasable programmable read only memory (EEPROM), a high-speed clock, analog-to-digital (A/D) circuitry, digital-to-analog (D/A) circuitry, input/output (I/O) circuitry, power electronics/transformers, and/or signal conditioning and buffering electronics. The individual control/processing routines resident in the electronic controller 40 or readily accessible thereby may be stored in ROM or other suitable tangible memory locations and/or memory devices, and may be automatically executed by associated hardware components of the controller 40 to provide the respective processing functionality.

FIGS. 2 and 3 generally represent two potential configurations of a data matrix 50 that may be generated by the electronic controller 40. As illustrated, FIG. 2 represents a Data Matrix ECC200 Code 52 generated according to ISO/IEC 16022:2006, and FIG. 3 represents a QR Code 54 generated according to ISO/IEC 18004:2006. Both matrices 52, 54 have been encoded to represent the text “Serial No.; Model No.” In one configuration, the electronic controller 40 may be configured to generate the two-dimensional data matrix 50 by encoding unique part identifying information into a 2D form. The specific encoding techniques may be performed according to industry standards for the chosen code-type (e.g., according to the previously mentioned international standards). These encoding techniques may include generating and/or integrating error correcting information into the 2D data matrix 50 to provide redundancy and/or robustness to the 2D pattern. In one configuration, the error correcting information may be according to a Reed-Solomon Error Correcting Code and/or may include various parity bits, patterns, or underlying encoding methods that may aid in error correction/rejection.

The 2D data matrix 50 may be generated to encode various part identifying information. For example, the data matrix 50 may represent a part serial number (i.e., a unique identifier that may be different for each physical part produced); a part model identifier (i.e., an identifier that may indicate the make/model of the part design); a manufacturing location identifier (i.e., an identifier that may indicate the manufacturing facility/location where the part was cast); and/or a manufacturing date identifier (i.e., an identifier representing the date on which the part was cast).

Once the 2D data matrix 50 is generated by the controller 40, the controller 40 may then control the laser engraving device 30 to engrave the mirror image of a representation of the 2D data matrix into the inner face 22 of the mold 20. For example, as shown in FIGS. 2 and 3, the darkened portions (generally at 56) may be engraved into the inner face 22 of the mold 20. In one configuration, the engraved portions may be engraved to a depth of between approximately 0.5 mm and approximately 1.5 mm below the surface of the inner face 22. As may be understood, laser engraving involves selectively removing material from the inner face 22 of the mold 20. This is different from other marking methods, such as dot peening, which may selectively compress or displace material by impinging/imprinting a rigid punch into the inner face 22, or etching, which may merely affect the surface of the inner face 22 (i.e., and not penetrate substantially deeper than the surface). The engraved mold 20 may then be used to form a serialized cast part having an integrally formed 2D data matrix 50 by receiving molten metal within the part cavity 24.

In one configuration, as generally illustrated in FIG. 1, the encoded identifying information 60, such as for example, the part serial number, may be stored in a computer readable database 62 associated with the electronic controller 40. In this manner, the system 10 may register and/or maintain a log of all created cast parts. By uniquely registering each serialized part may, enhanced part tracking, statistical quality control, and/or life-cycle analyses may be available. For example, during the casting process, one or more manufacturing parameters 64 may be monitored (such as via associated sensors 66) and stored into the computer readable database 62. These manufacturing parameters 64 may include, for example, one or more mold temperatures and/or temperature profiles, a mold cooling rate, a batch identification number for the molten metal, or similar manufacturing characteristics. These monitored parameters 64 may be associated with the recorded identifying information 60 of the cast part created. Such correlations may aid in post-manufacturing statistical quality inspections and/or root cause analyses.

In another configuration, such as generally illustrated in FIG. 4, alphanumeric part identifying information 70 may be engraved into the inner face 22 of the mold 20 proximate to the engraved representation 74 of the 2D data matrix 50. The alphanumeric part identifying information 70 may include information that may be encoded into the 2D data matrix 50, such as, for example, a part serial number 76 and/or a part model number 78.

FIG. 5 generally illustrates a method 100 for serializing a cast part. As shown, the method 100 includes providing a mold 20 for a metal casting (step 102), where the mold includes an inner face 22 that partially defines a part cavity 24. An electronic controller 40 may then generate a two-dimensional data matrix 50 (step 104) that may include, for example, both error correcting information and part identifying information. The electronic controller 40 may then control a laser engraving device 30 to engrave a representation of the two-dimensional data matrix 50 into the inner face of the mold (step 106). In one configuration, the representation may actually be a mirror image of the generated/desired data matrix 50. Following the engraving in step 106, a serialized part may be formed in step 108 by pouring molten metal into the part cavity of the mold. The molten metal may fill the part cavity including the engraved representation of the two-dimensional data matrix.

In addition to merely forming the serialized part, the method 100 may further include storing the part serial number in a computer readable database (step 110), monitoring at least one manufacturing parameter associated with the forming of the serialized part (step 112); storing the at least one monitored manufacturing parameter in the computer readable database (step 114); and associating the stored part serial number with the at least one stored manufacturing parameter (step 116).

While the best modes for carrying out the invention have been described in detail, those familiar with the art to which this invention relates will recognize various alternative designs and embodiments for practicing the invention within the scope of the appended claims. It is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative only and not as limiting. 

1. A method of serializing a cast part comprising: providing a mold for a metal casting, the mold including an inner face partially defining a part cavity; generating, using an electronic controller, a two-dimensional data matrix, the two-dimensional data matrix including error correcting information, and part identifying information; laser engraving a substantially mirror image representation of the two-dimensional data matrix into the inner face of the mold to a depth of between approximately 0.5 mm and approximately 1.5 mm; laser engraving alphanumeric part identifying information into the inner face of the mold proximate to the engraved representation of the two-dimensional data matrix, the two-dimensional data matrix further including the alphanumeric part identifying information; and forming a serialized part by pouring molten metal into the part cavity of the mold, the molten metal filling the part cavity including the engraved representation of the two-dimensional data matrix and the alphanumeric part identifying information.
 2. The method of claim 1, wherein the error correcting information is generated according to a Reed-Solomon Error Correcting Code.
 3. The method of claim 1, wherein the part identifying information includes a part serial number and a part model identifier.
 4. The method of claim 3, wherein the part identifying information further includes a manufacturing location identifier and a manufacturing date identifier.
 5. The method of claim 3, further comprising storing the part serial number in a computer readable database.
 6. The method of claim 5, further comprising monitoring at least one manufacturing parameter associated with the forming of the serialized part; storing the at least one monitored manufacturing parameter in the computer readable database; and associating the stored part serial number with the at least one stored manufacturing parameter.
 7. The method of claim 6, wherein the at least one monitored manufacturing parameter includes at least one of a mold temperature and cooling rate.
 8. The method of claim 1, wherein the two-dimensional data matrix is a QR Code generated according to ISO/IEC 18004:2006.
 9. The method of claim 1, wherein the two-dimensional data matrix is a Data Matrix ECC200 Code generated according to ISO/IEC 16022:2006.
 10. (canceled)
 11. The method of claim 1, wherein the mold includes sand and a bonding agent.
 12. (canceled)
 13. A system for serializing a cast part comprising: a mold for a creating a cast metal part, the mold including an inner face partially defining a part cavity; an electronically controlled laser engraving device configured to selectively engrave the inner face of the mold; an electronic controller configured to: generate a two-dimensional data matrix, the two-dimensional data matrix including error correcting information, and part identifying information; control the laser engraving device to engrave a representation of the two-dimensional data matrix into the inner face of the mold; and wherein the engraved mold is used to form a serialized cast part having an integrally formed two-dimensional data matrix upon receipt of molten metal within the part cavity.
 14. The system of claim 13, wherein the part identifying information includes a part serial number and a part model identifier.
 15. The system of claim 14, wherein the mold is a single use mold configured to form a single cast part, and wherein the serial number is unique to the single use mold.
 16. The system of claim 15, wherein the single use mold includes sand and a bonding agent.
 17. The system of claim 13, wherein the two-dimensional data matrix is a QR Code generated according to ISO/IEC 18004:2006.
 18. The system of claim 13, wherein the two-dimensional data matrix is a Data Matrix ECC200 Code generated according to ISO/IEC 16022:2006.
 19. The system of claim 1, wherein the electronic controller is configured to control the laser engraving device to engrave the representation of the two-dimensional data matrix to a depth of between approximately 0.5 mm and approximately 1.5 mm.
 20. A method of serializing a cast part comprising: providing a mold for a metal casting, the mold including an inner face partially defining a part cavity; generating, using an electronic controller, a two-dimensional data matrix, the two-dimensional data matrix including error correcting information, and part identifying information, the two-dimensional data matrix including a QR Code generated according to ISO/IEC 18004:2006 or a Data Matrix ECC200 Code generated according to ISO/IEC 16022:2006; laser engraving a substantially mirror image representation of the two-dimensional data matrix into the inner face of the mold to a depth of between approximately 0.5 mm and approximately 1.5 mm; laser engraving alphanumeric part identifying information into the inner face of the mold proximate to the engraved representation of the two-dimensional data matrix, the two-dimensional data matrix further including the alphanumeric part identifying information; and forming a serialized part by pouring molten metal into the part cavity of the mold, the molten metal filling the part cavity including the engraved representation of the two-dimensional data matrix and the alphanumeric part identifying information. 